Friday, November 22

How Industrial Air Compressors Are Different

Industrial air compressors, like the ones Zorn Compressor provides our customers, are different from the compressors you may find on the shelf of your local hardware store. These industrial air compressors differ in sizes and applications. Let’s learn more about this:

Air Compressor Classifications

Consumer-grade: these air compressors are generally single-stage models that can be used for household tasks such as inflating tires.
Professional-grade: these air compressors supply more power and higher pressurized air than consumer-grade models. They can be single-stage or two-stage reciprocating or rotary screw units. These compressors can run several air tools at a time with intermittent use.
Industrial-grade: these compressors provide the highest level of power and air pressurization to carry out many different manufacturing processes or heavy-duty applications. These units are designed to provide a steady flow of compressed air for long periods of time.

What Is an Industrial Air Compressor

An industrial air compressor is an air compressor that can be utilized for large, commercial tasks. They are designed to increase air pressure, converting power into potential energy, using this pressurized air to power tools, machinery, and other industrial processes that require more air than a small consumer-grade or professional-grade compressor can provide.

Types of Industrial Compressors

Industrial air compressors can come in a variety of sizes, designs, and motor types. Different industrial compressor technologies can provide different features and power, depending on the compressor and its application.

There are two main classifications of industrial air compressors: positive displacement and dynamic.

Positive Displacement Compressors

Rotary Screw Compressors

Rotary screw compressors are one of the most common industrial air compressors. These machines utilize rotating spiral screws to compress the air before it is expelled. These machines can come in oil lubricated or oil-free units. You can learn more about rotary screw compressors in our blog post: “All You Need to Know About Rotary Screw & Reciprocating Air Compressors.”

Reciprocating (Piston) Compressors

Reciprocating compressors are also a common industrial air compressor option. They utilize a crankshaft driven piston to compress the air before it gets put to use. These machines can come in single- or two-stage units. You can learn more about reciprocating compressors in our blog post: “All You Need to Know About Rotary Screw & Reciprocating Air Compressors.”

Rotary Vane Compressors

Rotary vane compressors are similar to rotary screw compressors but are less common. These machines utilize adjustable vanes that are located on a drive shaft to compress the air.

Scroll Compressors

Scroll compressors are smaller machines that use two smaller spirals (scrolls) that work together to compress the air. One scroll will stay stationary while the other moves inside the stationary scroll controlled by a crank shaft.

Dynamic Compressors

Centrifugal Compressors

Centrifugal compressors utilize a radial design that relies on a rotating impeller with radial blades to perform the compression process. These machines can be single- or multi-stage units.

Axial Compressors

Axial compressors are fairly uncommon units in the industrial air compressor sector compared to the other machines we discussed. These compressors are gas powered units used to continuously pressurize gases by allowing gas or air to flow parallel to the shaft axis through a series of rotating and stationary blades.

Applications of Small Air Compressors

• Adding air to tires or inflatables
• Pressure washing
• Small woodworking projects
• Powering handheld pneumatic tools
• Airbrush painting
• Spreading weed killers & fertilizers

Applications of Industrial Air Compressors

Below is a list of a few major industries that rely on compressed air and the processes compressed air assists with! This list is just a small fraction of all the roles an air compressor may play in the industrial and commercial world.

Choosing the Right Industrial Compressor

Application Pressure & Flow Requirements
Each unique industry and application will have a unique flow requirement to fulfill the demand. It is important to know your required pressure and flow requirements to efficiently and effectively carry out the tasks you will be having your compressor perform. This will help you determine the right size and power of the air compressor you need.
Size Allowance
The space you plan to locate your compressor in may dictate the footprint you need your compressor to carry. Air compressors come in a range of sizes and a range of mounting styles to fit best in your facility.
Drive & Control System Preferences
The drive controls and operation standards for each air compressor carry differing energy efficiencies when put to work in each application. You will want to choose a different control type depending on how continuously you run your compressor and how largely your demand fluctuates. To learn more about this, read our blog post on control types: “Compressor Controls Explained.”
Air Quality Needs
Some industries require higher air quality standards. For example, a hospital utilizing air compressors to deliver breathing air to patients would require the highest quality of air, compared to a lumberyard utilizing compressed air to carry out sawing and cutting duties. Air quality needs may dictate whether you need to use an oil-lubricated, oil-free, or oil-less compressor. You can learn more about these air compressor mechanics in our blog post, “Back to Compressed Air School Part 3: Air Compressor Mechanics.”
Maintenance Requirements
Each model of air compressor requires maintenance of some sort. However, the frequency and cost of this maintenance may differ between each compressor type, size, and brand. Before choosing the right compressor for your facility, you will want to speak with your compressed air expert on the maintenance requirements of the air compressors you are looking to add to your facility.
Cost of Ownership
Cost of ownership is a complex topic in the compressed air world as so many factors contribute to this number. Energy consumption is the highest percentage of your cost of owning an air compressor. Read our blog post, “The Cost of Compressed Air,” to learn more about what contributes to this cost in order to help you estimate potential costs of ownership in finding the right air compressor for your facility.

ZORN'S PROMISE

Zorn is the Midwest leader of custom, engineered compressed air and vacuum solutions. We provide the best customer experience by understanding your applications and needs and offering an unparalleled commitment to customer satisfaction.

Our comprehensive product and service solutions keep you running 24/7.

Reliable equipment
Trusted brands
Seamless, easy installation
Post-sales support
Local, 24/7 service

Our compressed air experts look forward to meeting you to discuss your equipment and support needs. Please contact us directly at (262) 695-7000 with any questions or to schedule service for your system moving forward.

Share On Social Media

Related Resources

< Return to Resources

need a compressed air solution?

First Name *

Last Name *

City *

State *

Email Address *

Phone

Company *

What can we help you with? *

Describe your service or equipment needs. *